i have friends doing toys. none of them are using 3D. still. [edit: For them] it's all 2D orthos and getting sculpted models from China. lots of handwork. i did get a call from Fisher-Price couple years back. they wanted Pro/E surfacing services and advice. but their surfaces weren't anything complex. they were just new to using CAD for them i guess.

personally i think some of the things i've done moving poly models to Pro/E are a nice solution. like those samples i posted a while back of one toy. hoping to do something with that process eventually.